Generac MLT4060 Power Zone Control Operating instructions

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 1

SKA0052 Instructions # 53514

Subject

Instructions for exchanging original control box with Power Zone™ control box.

Models Affected

MLT4060K light tower

Table of Contents

Page

Introduction ..................................................................................................................................... 1

Recommended Tools ...................................................................................................................... 2

SKA0052 Kit Components .............................................................................................................. 2

Remove Old Control Box ................................................................................................................ 3

Install Power Zone Control Box..................................................................................................... 13

Power Zone Controller .................................................................................................................. 22

Manually Starting Unit................................................................................................................... 29

Auto (Remote) Starting of Unit ...................................................................................................... 30

Light Operation.............................................................................................................................. 31

Auto Exercise Timer...................................................................................................................... 31

Resetting Maintenance Alarms ..................................................................................................... 34

Shutting Down the Unit ................................................................................................................. 35

AC Wiring Diagram ....................................................................................................................... 36

DC Wiring Diagram ....................................................................................................................... 37

Introduction

The following instructions illustrate exchanging original control box with Power Zone™ control box on MLT4060K

light tower.

Note: Before beginning these procedures, verify kit components listed on page 2 are present. If items are missing,

contact Generac Mobile Products LLC at 1-800-926-9768.

WARNING

Consult Manual. Read and understand manual completely before using product.

Failure to completely understand manual and product could result in death or serious

injury. (000100a)

WARNING

Accidental Start-up. Disconnect the negative battery cable, then the positive battery

cable when working on unit. Failure to do so could result in death or serious injury.

(000130)

WARNING

California Proposition 65. Engine exhaust and some of its constituents are known to

the state of California to cause cancer, birth defects, and other reproductive harm.

(000004)

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 2

WARNING

California Proposition 65. This product contains or emits chemicals known to the

state of California to cause cancer, birth defects, and other reproductive harm.

(000005)

Recommended Tools

SKA0052 Kit Components

Figure 1 - SKA0052 Kit Components

Item Part No. Qty Description Notes

1 69841 1 Assembly, complete box, Kubota, 6kw, PZ

-- 49613 8 Cable tie, 8.00 in. x .142 - red

• 1/2 in. wrench • 7/16 in. wrench

• 9/16 in. wrench • 3/8 in. wrench

• 9/16 in. socket with extension • Diagonal cutter

• 7 mm wrench • Phillips screwdriver

• 17 mm wrench

1

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 3

Remove Old Control Box

1. Verify unit is OFF.

2. See Figure 2. Disconnect negative battery cable and secure terminal away from battery.

Figure 2 - Negative Battery Cable, Secured Away from Battery

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 4

3. Disconnect all engine harness wires, as follows.

Note: When disconnecting an engine harness wire, cut and discard cable-ties securing the wire.

a. See Figure 3. Disconnect violet/yellow and black/white wires that connect to fuel pump wires.

Figure 3 - Fuel Pump Wires

b. See Figure 4. Disconnect coolant temperature switch wire.

Figure 4 - Coolant Temperature Sensor Wire (Top of Engine)

Item Description

A Fuel pump wires

B Violet/yellow wire

C Black/white wire

A

B

C

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 5

c. See Figure 5. Disconnect glow plug wire.

Figure 5 - Glow Plug Wire

d. See Figure 6. Disconnect fuel solenoid plug from the fuel solenoid.

Figure 6 - Fuel Solenoid Plug

e. See Figure 7. Disconnect engine ground wire.

Figure 7 - Engine Ground Wire

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 6

f. See Figure 8.

• Disconnect red/violet wire from alternator.

• Disconnect orange and red/white wires from starter.

Figure 8 - Alternator and Starter Wires

g. See Figure 9. Disconnect oil pressure switch wire.

Figure 9 - Oil Pressure Switch Wire

Item Description

A Red/violet wire (alternator)

B Orange wire (starter)

C Red/white wire (starter)

A

B

C

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 7

4. Disconnect generator box wires, as follows.

a. See Figure 10. Remove generator box cover. Retain cover and hardware.

Figure 10 - Generator Box Cover

b. See Figure 11.

i. Disconnect black, white, and red wires from terminals.

ii. Loosen strain relief.

Figure 11 - Generator Box Wires and Strain Relief

c. Remove wires from box.

Item Description

A Black, white, and red wires

B Strain relief

A

B

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 8

5. See Figure 12. Disconnect both wires from ground stud in unit chassis. Retain hardware.

Figure 12 - Ground Wire to Chassis Ground Stud

Item Description

A Control box ground wire

B Ground stud in unit chassis

Secures two ground wires—control box and generator box

A

B

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 9

6. See Figure 13. On back of control box, loosen the upper and middle strain reliefs.

Figure 13 - Control Box Strain Reliefs

7. See Figure 14. Remove screws securing panel to control box. Open control box.

Figure 14 - Screws Securing Panel to Control Box

Item Strain Relief Description Cable Identification

A Upper Mast

B Middle Transformer

C Lower Generator box

D Side Engine harness

D

A

B

C

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 10

8. See Figure 15. In control box, disconnect all wires passing through upper and middle strain reliefs.

Figure 15 - Wires Passing Through Upper and Middle Strain Reliefs

9. See Figure 16. Remove cables from upper and middle strain reliefs.

Note: Cut cable-ties as necessary to ease removal of cables.

Figure 16 - Remove Cables

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 11

10. See Figure 17. Remove hardware securing control box to unit. Retain hardware and control box.

Figure 17 - Control Box to Unit: Four Hardware Locations

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 12

11. Choose the applicable step:

• For units with Auto-Light unit on control box:

See Figure 18. Remove and retain manual holder.

Figure 18 - Manual Holder on Box With Auto-Light Unit

• For units without Auto-Light unit:

See Figure 19. Remove and retain all manual holder components and hardware from control box.

Figure 19 - Manual Holder on Box Without Auto-Light Unit

12. Discard control box and remaining components.

Item Description

A Manual holder

B Auto-Light unit

A

B

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 13

Install Power Zone Control Box

1. Open control panel on new control box (PN 69841).

2. See Figure 20. Near top of box, locate bolt and nut that pass through box. Then, do the following:

• Remove and retain nut

• Leave screw in place

Figure 20 - Location of Bolt and Nut

3. Obtain manual holder parts retained in step 11 of Remove Old Control Box.

Item Description

ABolt

BScrew

A

B

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 14

4. See Figure 21. Attach manual holder to control box, as shown.

Note: Auto-Light units do not have all parts shown below. To obtain missing parts, contact Technical Service and

order the needed part numbers, provided in the table below.

Figure 21 - Manual Holder Components

Item PN Description

A 60690 Screw

B 60698 Washer

C 10241 Clamp

D— Nut

• Native to control box

• Removed and retained in step 2

E 60698 Split-lock washer

F 60140 Nut

G — Screw—native to control box

H 32731B Bracket

I — Manual holder—retained in step 11 of Remove Old Control Box

A

B

C

F

B

E

G

D

H

I

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 15

5. See Figure 17. Install control box in unit with hardware retained in step 10 of Remove Old Control Box.

6. See Figure 22. Route the generator box cable and ground wire, as follows.

Figure 22 - Generator Box Cable and Ground Wire

• Cable: Route to generator box, through generator box strain relief, and into generator box

• Ground wire: Route to ground stud in unit chassis (Figure 12)

Note: Do not connect wires until instructed.

7. See Figure 11. Connect generator box wires, routed into generator box in step 6, to generator box terminals, in

the following order.

a. Black

b. White

c. Red

8. See Figure 10. Install generator box cover with hardware removed in step 4a of Remove Old Control Box.

9. Route mast cable into control box by way of top strain relief.

10. See Figure 23. Connect mast wires, as shown.

Figure 23 - Connect Mast Wires

Item Description

A Brown and white wires

B Yellow, red, blue, and black wires

C Green (ground) wire

A

B

C

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 16

11. Route transformer cable into control box, by way of middle strain relief.

12. See Figure 24. Connect transformer wires, as shown.

Figure 24 - Connect Transformer Wires

Note: Writing on the transformer wires identifies them as COMS, 120, or CAPS.

13. See Figure 25. Locate engine harness (exits control box through side strain relief). Connect wires, as follows.

Figure 25 - Engine Harness from Control box

a. See Figure 7. Connect ground wire to engine block.

b. See Figure 6. Connect fuel solenoid plug to fuel solenoid.

c. Route black/white wire with blue ring terminal to ground stud in unit chassis (Figure 12).

Note: Do not connect black/white wire until instructed.

Item Description

A COMS wires

B 120 wires

C CAPS wires

A

B

C

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 17

d. See Figure 26. Route gray/blue wire to coolant temperature switch, as shown. Secure wire to engine with

two cable-ties.

Note: The gray/blue wire is wrapped in black looming, as shown.

Figure 26 - Route Gray/Blue Wire to Coolant Temperature Switch

e. See Figure 5. Connect glow plug wire (black wire with blue ring terminal) to rail.

Item Description

A Suggested route of gray/blue wire

B Destination of gray/blue wire—coolant temperature switch

A

B

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 18

f. See Figure 27. Connect fuel pump wires and secure with cable-tie, as shown.

Figure 27 - Fuel Pump Wires and Securing Them

Item Description Notes

A Unit wire—Black

Unit wires are bound together in black shrink-wrap,

forming a black cable that originates at the fuel pump.

B Unit wire—Red

C Engine harness wire—Black/white

D Engine harness wire—Violet/yellow

E Fuel filter/pump bracket

F Zip tie Secures all wires to fuel filter/pump bracket

Connecting Fuel Pump Wires

Engine Harness Wire To Unit Wire

Black/white Black

Violet/yellow Red

C

D

A

B

E

F

5/6/16 Generac Mobile Products LLC • 1-800-926-9768 19

g. See Figure 28. Eliminate most slack in engine harness wires (on fuel solenoid side of engine) by bundling

and cable-tying the wires, as shown.

When bundling wires, allow some slack to remain or damage to wires and connections may

result.

Figure 28 - Bundle and Cable-Tie Harness Wires

h. See Figure 29. Connect orange wire with green plug to alternator.

Figure 29 - Alternator Connection

i. See Figure 30. Connect gray/violet wire to oil pressure switch.

Figure 30 - Connect Oil Pressure Switch Wire

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j. See Figure 31. Connect red wires to starter, as follows.

Figure 31 - Starter Wires

i. See Figure 32. Attach blue and yellow ring terminals to main starter stud.

ii. Attach spade terminal to piggyback terminal; then attach to starter solenoid terminal.

Figure 32 - Connection Points on Starter

Item Wire Description

A Ring terminal—yellow

B Spade terminal

C Piggyback terminal

D Ring terminal—blue

Item Description

A Starter solenoid terminal

B Main starter stud

A

B

C

D

A

B

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Generac MLT4060 Power Zone Control Operating instructions

Generac MLT4060 Power Zone Control Operating instructions

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